Rheem Condensor Service Manual 15PJL

8/18/2019 Rheem Condensor Service Manual 15PJL

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15 SEER SERIESHEAT PUMPS

1

1

⁄ 2 - 5 TONS FEATURINGEARTH-FRIENDLY R-410A REFRIGERANT R-410

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!!

DO NOT DESTROY THIS MANUAL

PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO

QUALIFIED, LICENSED SERVICE PERSONNEL FOR

PROPER INSTALLATION, ADJUSTMENT AND OPERATIONOF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY

BEFORE ATTEMPTING INSTALLATION OR OPERATION.

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT

IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR

MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL

SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH.

WARNING!

ISO 9001:2008

92-20522-80

SUPERSEDES 92-20522-80

INSTALLATION INSTRUCTIONS



1.0 SAFETY INFORMATION

! WARNINGThe manufacturer’s warranty does not cover any damage or defect to theheat pump caused by the attachment or use of any componentsAccessories or devices (other than those authorized by the manufacturer) into, onto or in conjunction with the heat pump. You should be awarethat the use of unauthorized components, accessories or devices mayadversely affect the operation of the heat pump and may also endangerlife and property. The manufacturer disclaims any responsibility for suchloss or injury resulting from the use of such unauthorized componentsaccessories or devices.

! WARNINGDisconnect all power to unit before starting maintenance. Failure to do so

can cause electrical shock resulting in severe personal injury or death.

CAUTIONWhen coil is installed over a finished ceiling and/or living area, it isrecommended that a secondary sheet metal condensate pan beconstructed and installed under entire unit. Failure to do so can resultin property damage.

! WARNINGThe unit must be permanently grounded. Failure to do so can cause elec-trical shock resulting in severe personal injury or death.

CAUTIONSingle-pole contactors are used on all standard single-phase units upthrough 5 tons. Caution must be exercised when servicing as only one legof the power supply is broken with the contactor.

! WARNINGTurn off electric power at the fuse box or service panel before making anyelectrical connections.

Also, the ground connection must be completed before making line volt-age connections. Failure to do so can result in electrical shock, severepersonal injury or death.

! WARNINGThese instructions are intended as an aid to qualified licensed servicepersonnel for proper installation, adjustment and operation of this unitRead these instructions thoroughly before attempting installation or operation. Failure to follow these instructions may result in improper installa-

tion, adjustment, service or maintenance possibly resulting in fire, electri-cal shock, property damage, personal injury or death.



2.0 GENERAL

2.1 CHECKING PRODUCT RECEIVEDUpon receiving unit, inspect it for any shipping damage. Claims for damage, eitherapparent or concealed, should be filed immediately with the shipping company.Check heat pump model number, electrical characteristics and accessories todetermine if they are correct. Check system components (evaporator coil, condens-ing unit, evaporator blower, etc.) to make sure they are properly matched.The infor-mation contained in this manual has been prepared to assist in the proper installa-tion, operation and maintenance of the heat pump system. Improper installation, orinstallation not made in accordance with these instructions, can result in unsatisfac-

tory operation and/or dangerous conditions, and can cause the related warranty notto apply.

Read this manual and any instructions packaged with separate equipment requiredto make up the system prior to installation. Retain this manual for future reference.

To achieve optimum efficiency and capacity, the indoor cooling coils listed in theheat pump specification sheet should be used.

2.2 APPLICATIONBefore installing any heat pump equipment, a duct analysis of the structure and aheat gain calculation must be made. A heat gain calculation begins by measuring allexternal surfaces and openings that gain heat from the surrounding air and quanti-fying that heat gain. A heat gain calculation also calculates the extra heat loadcaused by sunlight and by humidity removal.

There are several factors that the installers must consider:• Outdoor unit location • Proper equipment evacuation• System refrigerant charge • Indoor unit airflow• Indoor unit blower speed • Supply and return air duct design and sizing• System air balancing • Diffuser and return air grille location and sizing

! WARNINGThe manufacturer’s warranty does not cover any damage or defect to theheat pump caused by the attachment or use of any components.Accessories or devices (other than those authorized by the manufactur-er) into, onto or in conjunction with the heat pump. You should be awarethat the use of unauthorized components, accessories or devices mayadversely affect the operation of the heat pump and may also endanger

life and property. The manufacturer disclaims any responsibility for suchloss or injury resulting from the use of such unauthorized components,accessories or devices.

MATCH ALL COMPONENTS:

• OUTDOOR UNIT

• INDOOR COIL/METERING DEVICE

• INDOOR AIR HANDLER/FURNACE

• REFRIGERANT LINES

4



Height “H” (in.) [mm]

DIMENSIONAL DATA

Length “L” (in.) [mm]

Width “W” (in.) [mm]

BASE PAN (BOTTOM VIEW)DO NOT OBSTRUCT DRAIN HOLES

(SHADED).

15 SEER 18, 24 30 36, 42, 48, 60

261 / 4 [666.7]

275 / 8 [701.6]

275 / 8 [701.6]

273 / 8 [695.3] 353 / 8 [898.5]

315 / 8 [803.2] 315 / 8 [803.2]

315 / 8 [803.2] 315 / 8 [803.2]

FIGURE 1DIMENSIONS

2.3 DIMENSIONS (SEE FIGURE 1)

AIR DISCHARGE: ALLOW60” [1524 mm] MINIMUMCLEARANCE.

L

H

SEE DETAIL

w

A-00008

SERVICE ACCESS

ALLOW 24” [609.6 mm]CLEARANCE

AIR INLETS(LOUVERED PAN-ELS) ALLOW 6”[152.4 mm]MINIMUMCLEARANCE

2"[50.8 mm]

BASERAIL*

NOTE: GRILLE APPEARANCEMAY VARY.

*The 3, 31 ⁄ 2, 4 & 5 tonmodels do not featurea baserail.

*NOTE: “H” DIMENSION INCLUDESBASERAILS AND/OR BASEPAN.

*



3.0 LOCATING UNIT3.1 CORROSIVE ENVIRONMENTThe metal parts of this unit may be subject to rust or deterioration if exposed to acorrosive environment. This oxidation could shorten the equipment’s useful life.Corrosive elements include, but are not limited to, salt spray, fog or mist in seacoastareas, sulphur or chlorine from lawn watering systems, and various chemical conta-minants from industries such as paper mills and petroleum refineries.

If the unit is to be installed in an area where contaminants are likely to be a prob-lem, special attention should be given to the equipment location and exposure.

• Avoid having lawn sprinkler heads spray directly on the unit cabinet.• In coastal areas, locate the unit on the side of the building away from the water-

front.

• Shielding provided by a fence or shrubs may give some protection, but cannotviolate minimum airflow and service access clearances.

• Elevating the unit off its slab or base enough to allow air circulation will helpavoid holding water against the basepan.

Regular maintenance will reduce the build-up of contaminants and help to protectthe unit’s finish.

NOTES:

20 Fins per inch [mm]

Factory charged for 15 ft. [4.6 m] of line set

2.4 ELECTRICAL & PHYSICAL DATA (SEE TABLE 1)

ModelNumber

PhaseFrequency (Hz)Voltage (Volts)

Rated LoadAmperes

(RLA)

Locked RotorAmperes

(LRA)

Fan MotorFull LoadAmperes

(FLA)

MinimumCircuit

AmpacityAmperes

MinimumAmperes

MaximumAmperes

Face AreaSq. Ft.

[m2]

No.Rows

CFM[L/s]

Refrig.Per

CircuitOz. [g]

NetLbs. [kg]

ShippingLbs. [kg]

Fuse or HACRCircuit Breaker

Outdoor Coil WeightCompressor

ELECTRICAL DATA PHYSICAL DATA

18 1-60-208/230 9/9 48 0.8 13/13 15/15 20/20 13.72 [1.27] 1 2590 [1222] 95.6 [2710] 154 [69.9] 164 [74.4]

24 1-60-208/230 13.5/13.5 58.3 0.8 18/18 25/25 30/30 13.72 [1.27] 1 2590 [1222] 94.2 [2671] 155 [70.3] 165 [74.8]

30 1-60-208/230 12.8/12.8 64 1 18/18 25/25 25/25 16.39 [1.52] 1 2595 [1225] 114.5 [3246] 169 [76.7] 181 [82.1]

36 1-60-208/230 16.7/16.7 79 1.4 23/23 30/30 35/35 21.85 [2.03] 1 3000 [1416] 138 [3912] 193 [87.5] 207 [93.9]

42 1-60-208/230 17.9/17.9 112 1.9 25/25 30/30 40/40 21.85 [2.03] 1 3575 [1687] 146.5 [4153] 210 [95.3] 224 [101.6]

48 1-60-208/230 19.9/19.9 109 1 26/26 35/35 45/45 21.85 [2.03] 1 3575 [1687] 229.2 [6498] 2 10 [95.3] 224 [101.6]

60 1-60-208/230 21.4/21.4 135 2.8 30/30 35/35 50/50 21.85 [2.03] 2 3925 [1852] 279 [7910] 264 [119.8] 278 [126.1]

Rev. 2/3/2010

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TABLE 1ELECTRICAL AND PHYSICAL DATA – 13 SEER



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• Do not obstruct the bottom drain opening in the heat pump base pan. It isessential to provide defrost condensate drainage to prevent possible refreezingof the condensation. Provide a base pad for mounting the unit, which is slightlypitched away from the structure. Route condensate off the base pad to an areawhich will not become slippery and result in personal injury.

• Where snowfall is anticipated, the heat pump must be elevated above the basepad to prevent ice buildup that may crush the tubing of the heat pump coil orcause fin damage. Heat pump units should be mounted above the averageexpected accumulated snowfall for the area.

3.5 CUSTOMER SATISFACTION ISSUES

• The heat pump should be located away from the living, sleeping and recre-

ational spaces of the owner and those spaces on adjoining property.• To prevent noise transmission, the mounting pad for the outdoor unit should

not be connected to the structure, and should be located sufficient distanceabove grade to prevent ground water from entering the unit.

3.6 UNIT MOUNTINGIf elevating the heat pump, either on a flat roof or on a slab, observe thefollowing guidelines.

• The base pan provided elevates the heat pump 2” [50.8 mm] above the basepad.

• If elevating a unit on a flat roof, use 4” x 4” [101.6 mm x 101.6 mm] (or equiva-lent) stringers positioned to distribute unit weight evenly and prevent noise andvibration (see Figure 2).

NOTE: Do not block drain openings shown in Figure 1.

• If unit must be elevated because of anticipated snow fall, secure unit and ele-vating stand such that unit and/or stand will not tip over or fall off. Keep in mindthat someone may try to climb on unit.

3.7 FACTORY-PREFERRED TIE-DOWN METHOD FOR OUTDOOR UNITSIMPORTANT: The Manufacturer’s approved/recommended method is a guide to securingequipment for wind and seismic loads. Other methods might provide the same result, butthe Manufacturer’s method is the only one endorsed by the Manufacturer for securingequipment where wind or earthquake damage can occur. Additional information is avail-able in the PTS (Product Technical Support) section of the Manufacturer’s websiteRheemote.net and can be found as a listing under each outdoor model. If you do nothave access to this site, your Distributor can offer assistance.

FIGURE 2RECOMMENDED ELEVATED INSTALLATION



4.0 REFRIGERANT CONNECTIONSAll units are factory charged with Refrigerant 410A for 15 ft. [4.6 m] of line set. Amodels are supplied with service valves. Keep tube ends sealed until connectionto be made to prevent system contamination.

5.0 REPLACEMENT UNITSTo prevent failure of a new heat pump unit, the existing tubing system must be corectly sized and cleaned or replaced. Care must be exercised that the expansi

device is not plugged. For new and replacement units, a liquid line filter drier shobe installed and refrigerant tubing should be properly sized. Test the oil for acidpositive, a liquid line filter drier is mandatory.

6.0 INDOOR COILREFER TO INDOOR COIL MANUFACTURER’S INSTALLATION INSTRUCTION

IMPORTANT: The manufacturer is not responsible for the performance and opetion of a mismatched system, or for a match listed with another manufacturer’s co

6.1 LOCATIONDo not install the indoor coil in the return duct system of a gas or oil furnacProvide a service inlet to the coil for inspection and cleaning. Keep the coil pitch

toward the drain connection.

CAUTIONWhen coil is installed over a finished ceiling and/or living area, it isrecommended that a secondary sheet metal condensate pan beconstructed and installed under entire unit. Failure to do so can resulin property damage.



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7.0 INTERCONNECTING TUBING7.1 VAPOR AND LIQUID LINESKeep all lines sealed until connection is made.

Make connections at the indoor coil first.

Refer to Line Size Information in Tables 2 and 3 for correct size and multipliers to beused to determine capacity for various vapor line diameters and lengths of run. Thelosses due to the lines being exposed to outdoor conditions are not included.

The factory refrigeration charge in the outdoor unit is sufficient for 15 feet [4.6 m] of

interconnecting lines. The factory refrigeration charge in the outdoor unit is sufficientfor the unit and 15 feet [4.6 m] of standard size interconnecting liquid and vaporlines. For different lengths, adjust the charge as indicated below.

1/4” ± .3 oz. per foot [6.35 mm ± 8.5 g]

5/16” ± .4 oz. per foot [7.9 mm ± 11.3 g]

3/8” ± .6 oz. per foot [9.5 mm ± 17 g]

1/2” ± 1.2 oz. per foot [12.7 mm ± 34 g]

7.2 MAXIMUM LENGTH OF LINESThe maximum length of interconnecting line is 150 feet [45.7 m]. Always use theshortest length possible with a minimum number of bends. Additional compressoroil is not required for any length up to 150 feet [45.7 m].

NOTE: Excessively long refrigerant lines cause loss of equipment capacity.

7.3 VERTICAL SEPARATIONKeep the vertical separation to a minimum. Use the following guidelines wheninstalling the unit:

1. DO NOT exceed the vertical separations as indicated on Table 3.

2. It is recommended to use the smallest liquid line size permitted to minimize sys-tem charge which will maximize compressor reliability.

3. Table 3 may be used for sizing horizontal runs.

7.4 TUBING INSTALLATIONObserve the following when installing correctly sized type “L” refrigerant tubingbetween the condensing unit and evaporator coil:

• If a portion of the liquid line passes through a hot area where liquid refrigerantcan be heated to form vapor, insulating the liquid line is required.

• Use clean, dehydrated, sealed refrigeration grade tubing.

• Always keep tubing sealed until tubing is in place and connections are to bemade.

• Blow out the liquid and vapor lines with dry nitrogen before connecting to theoutdoor unit and indoor coil. Any debris in the line set will end up plugging theexpansion device.

• As an added precaution it is recommended that a high quality, bi-directional fil-ter drier is installed in the liquid line.

• Do not allow the vapor line and liquid line to be in contact with each other. This

causes an undesirable heat transfer resulting in capacity loss and increasedpower consumption. The vapor line must be insulated.

• If tubing has been cut, make sure ends are deburred while holding in a positionto prevent chips from falling into tubing. Burrs such as those caused by tubingcutters can affect performance dramatically, particularly on small liquid linesizes.

• For best operation, keep tubing run as short as possible with a minimum num-ber of elbows or bends.

• Locations where the tubing will be exposed to mechanical damage should beavoided. If it is necessary to use such locations, the copper tubing should behoused to prevent damage.



• If tubing is to be run underground, it must be run in a sealed watertight chase

• Use care in routing tubing and do not kink or twist. Use a tubing bender on tvapor line to prevent kinking.

• Route the tubing using temporary hangers, then straighten the tubing ainstall permanent hangers. Line must be adequately supported.

• The vapor line must be insulated to prevent dripping (sweating) and preveperformance losses. Armaflex and Rubatex are satisfactory insulations for tpurpose. Use 1/2” [12.7 mm] minimum insulation thickness, additional insution may be required for long runs.

• Check Table 2 for the correct vapor line size. Check Table 3 for the correct uid line size.

7.5 TUBING CONNECTIONS

Indoor coils have only a holding charge of dry nitrogen. Keep all tube ends sealuntil connections are to be made.

• Use type “L” copper refrigeration tubing. Braze the connections with acceptindustry practices.

• Be certain both refrigerant shutoff valves at the outdoor unit are closed.

• Clean the inside of the fittings before brazing.

• Remove the cap and schrader core from service port to protect seals from he

damage.• Use an appropriate heatsink material around the copper stub and the serv

valves before applying heat.

• IMPORTANT: Do not braze any fitting with the TEV sensing bulb attached.

• Braze the tubing between the outdoor unit and indoor coil. Flow dry nitroginto a service port and through the tubing while brazing.

• The service valves are not backseating valves. To open the valves, remove tvalve cap with an adjustable wrench. Insert a 3/16” [4.7 mm] or 5/16” [7.9 mm] hwrench into the stem. Back out counterclockwise.

• Replace the valve cap finger tight then tighten an additional 1/2 hex flat fometal-to-metal seal.

7.6 LEAK TESTING• Pressurize line set and coil through service fittings with dry nitrogen to 1

PSIG [1034.2 kPa] maximum. Leak test all joints using liquid detergent. Ileak is found, relieve pressure and repair.



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TABLE 2SUCTION LINE LENGTH/SIZE VS CAPACITY MULTIPLIER (R-410A)

NOTES:

*Standard line sizeUsing suction line larger than shown in chart will result in poor oil return and is not recommended.

5/8 [15.9] Opt.3/4* [19] Std.

—

5/8 [15.9] Opt.3/4* [19] Std.

—

5/8 [15.9] Opt.3/4* [19] Std.

7/8 [22.2] Opt.

5/8 [15.9] Opt.3/4* [19] Std.

7/8 [22.2] Opt.

3/4 [19] Opt.7/8* [22.2] Opt.

—

7/8 [22.2]* Std.1 1/8 Opt.

—

7/8 [22.2]* Std.1 1/8 [28.6] Opt.

—

Unit Size

Suction Line Connection Size

Suction Line Run - Feet [m]

3/4”[19] I.D.

3/4”[19] I.D.

3/4”[19] I.D.

3/4”[19] I.D.

7/8”[22.2] I.D.

7/8”[22.2] I.D.

7/8”[22.2] I.D.

1 1/2 Ton 2 Ton 2 1/2 Ton 3 Ton 3 1/2 Ton 4 Ton 5 Ton

Optional

25’ [7.6] Standard— Optional

Optional50’ [15.24] Standard

— OptionalOptional

100’ [30.5] Standard— Optional

Optional150’ [45.7] Standard

— Optional

1.00 1.00 1.00 1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00 1.00 1.00 1.00— — 1.00 — — — —

0.98 0.98 0.96 0.98 0.99 0.99 0.990.99 0.99 0.98 0.99 0.99 0.99 0.99— — 0.99 — — — —

0.95 0.95 0.94 0.96 0.96 0.96 0.970.96 0.96 0.96 0.97 0.98 0.98 0.98— — 0.97 — — — —

0.92 0.92 0.91 0.94 0.94 0.95 0.940.93 0.94 0.93 0.95 0.96 0.96 0.97— — 0.95 — — — —



TABLE 3LIQUID LINE SIZING (R-410A)

NOTES:

*Standard line size

N/A - Application not recommended.

Liquid Line Size

Outdoor unit above or below indoor coil(Heat Pump Only)

Total Equivalent Length - Feet [m]

Maximum Vertical Separation - Feet [m]

25 50 75 100 125 150

SystemCapacity

1 1/2 Ton

2 Ton

2 1/2 Ton

3 Ton

3 1/2 Ton

4 Ton

5 Ton

3/8” [9.5]

3/8” [9.5]

3/8” [9.5]

3/8” [9.5]

3/8” [9.5]

3/8” [9.5]

3/8” [9.5]

1/4 [6.4] 25 [7.6] 40 [12.2] 25 [7.6] 9 [2.7] N/A N/A5/16 [7.9] 25 [7.6] 50 [15.2] 62 [18.9] 58 [17.7] 53 [16.2] 49 [14.9]

3/8* [9.5] 25 [7.6] 50 [15.2] 75 [22.9] 72 [21.9] 70 [21.3] 68 [20.7]

1/4 [6.4] 23 [7.0] N/A N/A N/A N/A N/A

5/16 [7.9] 25 [7.6] 36 [10.9] 29 [8.8] 23 [7.0] 16 [4.9] 9 [2.7]

3/8* [9.5] 25 [7.6] 50 [15.2] 72 [21.9] 70 [21.3] 68 [20.7] 65 [19.8]

1/4 [6.4] 25 [7.6] N/A N/A N/A N/A N/A

5/16 [7.9] 25 [7.6] 49 [14.9] 38 [11.6] 27 [8.3] 17 [5.2] 6 [1.8]

3/8* [9.5] 25 [7.6] 50 [15.2] 68 [20.7] 65 [19.8] 62 [18.9] 58 [17.7]

5/16 [7.9] 25 [7.6] 50 [15.2] 37 [11.3] 22 [6.7] 7 [2.1] N/A

3/8* [9.5] 25 [7.6] 50 [15.2] 68 [20.7] 63 [19.2] 58 [17.7] 53 [16.2]

5/16 [7.9] 25 [7.6] 23 [7.0] 4 [1.2] N/A N/A N/A

3/8* [9.5] 25 [7.6] 50 [15.2] 43 [13.1] 36 [10.9] 30 [9.144] 24 [7.3]

3/8* [9.5] 25 [7.6] 46 [14.0] 38 [11.6] 30 [9.144] 22 [6.7] 15 [4.5]

1/2 [12.7] 25 [7.6] 50 [15.2] 56 [17.1] 55 [16.8] 53 [16.2] 52 [15.8]

3/8* [9.5] 25 [7.6] 50 [15.2] 56 [17.1] 44 [13.4] 32 [9.8] 20 [6.1]

1/2 [12.7] 25 [7.6] 50 [15.2] 75 [22.9] 81 [24.7] 79 [24.1] 76 [23.2]

Line Size

Connection Size(Inch I.D.) [mm]

Line Size

(Inch OD)[mm]



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8.0 DEMAND DEFROST CONTROL AND8.0 HIGH/LOW PRESSURE CONTROLSThe demand defrost control is a printed circuit board assembly consisting of solidstate control devices with electro-mechanical outputs. The demand defrost controlmonitors the outdoor ambient temperature, outdoor coil temperature, and the com-pressor run-time to determine when a defrost cycle is required.

Enhanced Feature Demand Defrost Control: Has high and low pressure controlinputs with unique pressure switch logic built into the microprocessor to providecompressor and system protection without nuisance lock-outs. Cycles the compres-

sor off for 5 seconds at the beginning and end of the defrost cycle to eliminate theincreased compressor noise caused by rapidly changiing system pressures whenthe reversing valve switches. See section 8.7 for diagnostic flash codes for the twodiagnostic LED’s provided on the control.

8.1 DEFROST INITIATION

A defrost will be initiated when the three conditions below are satisfied:

1) The outdoor coil temperature is below 35°F.

2) The compressor has operated for at least 34 minutes with the outdoor coil tem-perature below 35°F.

3) The measured difference between the ambient temperature and the outdoorcoil temperature exceeds a certain threshold.

Additionally, a defrost will be initiated if six hours of accumulated compressor run-timehas elapsed without a defrost with the outdoor coil temperature below 35°F.

8.2 DEFROST TERMINATION

Once a defrost is initiated, the defrost will continue until fourteen minutes haselapsed or the coil temperature has reached the terminate temperature. The termi-nate temperature is factory set at 70°F, although the temperature can be changedto 50°F, 60°F, 70°F or 80°F by relocating a jumper on the board.

8.3 TEMPERATURE SENSORS

The coil sensor is clipped to the top tube on the outdoor coil at the point feed by thedistribution tubes from the expansion device (short 3/8” dia. tube). The air sensor islocated on the defrost control board.

If the ambient sensor fails the defrost control will initiate a defrost every 34 minuteswith the coil temperature below 35°F.

If the coil sensor fails the defrost control will not initiate a defrost.

8.4 TEST MODE

The test mode is initiated by shorting the TEST pins. In this mode of operation, theenable temperature is ignored and all timers are sped up by a factor of 240. To initi-ate a manual defrost, short the TEST pins. Remove the short when the systemswitches to defrost mode. The defrost will terminate on time (14 minutes) or whenthe termination temperature has been achieved. Short TEST pins again to termi-nate the defrost immediately.

8.5 TROUBLE SHOOTING DEMAND DEFROST OPERATION

Set the indoor thermostat select switch to heat and thermostat lever to a call forheat.

Jumper the “test pins” to put the unit into defrost. If the unit goes into defrost andcomes back out of defrost, the indication is that the control is working properly.

If the unit did not go into defrost using the test pins, check to ensure that 24V isbeing supplied to the control board. If 24V is present then replace the control.



8.6 HIGH/LOW PRESSURE CONTROL MONITORING

Status of high and low pressure controls is monitored by the enhanced featudemand defrost control and the following actions are taken.

High Pressure Control (optional) – Provides active protection in both cooling aheating modes at all outdoor ambient temperatures. The high pressure control is automatic reset type and opens at approximately 610 psig and closes at appromately 420 psig. The compressor and fan motor will stop when the high pressucontrol opens and will start again if the high side pressure drops to approximat420 psig when the automatic reset high pressure control resets. If the high pressucontrol opens 3 times within a particular call for heating or cooling operation, t

defrost control will lock out compressor and outdoor fan operation.Low Pressure Control (standard) – Provides active protection in both heating acooling modes at all outdoor ambient temperatures. The low pressure control is automatic reset type and opens at approximately 15 psig and closes at appromately 40 psig. Operation is slightly different between cooling and heating modes

Cooling Mode: The compressor and fan motor will stop when the low pressucontrol opens and will start again when the low side pressure rises to appromately 40 psig when the low pressure control automatically resets. If the lopressure switch opens 3 times within a particular call for cooling operation, tdefrost control will lock out compressor and outdoor fan operation.

Heating Mode: The compressor and fan motor will stop when the low pressucontrol opens and will start again when the low side pressure rises to appromately 40 psig when the low pressure control automatically resets. If the lopressure switch trips 3 times within 120 minutes of operation during a particu

call for heating operation, the defrost control will lock out compressor and odoor fan operation. If the lock-out due to low pressure occurs at an outdoambient temperature below 5°F, the defrost control will automatically exit tlock-out mode when the outdoor ambient temperature rises to 5°F. This featuis necessary since the low pressure control could possibly heave opened duethe outdoor ambient being very low rather than an actual system fault.

Exiting Lock-Out Mode: To exit the lock-out mode, remove 24 volts to the defrocontrol by removing power to indoor air-handler/furnace or by shorting the twdefrost control test pins together.

8.7 ENHANCED FEATURE DEFROST CONTROL DIAGNOSTIC CODES

9.0 START-UP – CHECKING AIRFLOWThe air distribution system has the greatest effect on airflow. The duct system istotally controlled by the contractor. For this reason, the contractor should use only

industry-recognized procedures. The correct air quantity is critical to air conditionisystems. Proper operation, efficiency, compressor life, and humidity control depenon the correct balance between indoor load and outdoor unit capacity. Excessiveindoor airflow increases the possibility of high humidity problems. Low indoor airfloreduces total capacity and causes coil icing. Serious harm can be done to the compressor by low airflow, such as that caused by refrigerant flooding. Heat pump systems require a specified airflow. Each ton of cooling requires between 375 and 45cubic feet of air per minute (CFM). See the manufacturer’s spec sheet for rated aiflow for the system being installed. Duct design and construction should be carefudone. System performance can be lowered dramatically through bad planning orworkmanship. Air supply diffusers must be selected and located carefully. Theymust be sized and positioned to deliver treated air along the perimeter of the spacIf they are too small for their intended airflow, they become noisy. If they are notlocated properly, they cause drafts. Return air grilles must be properly sized to caair back to the blower. If they are too small, they also cause noise. The installers

LED 1 LED 2 Control Board Status

OFF OFF No Power

ON ON Coil Sensor FailureOFF ON Ambient Sensor FailureFLASH FLASH Normal

OFF FLASH Low Pressure Lockout (short test pins to reset)

FLASH OFF High Pressure Lockout (short test pins to reset)ON FLASH Low Pressure Control Open

FLASH ON High Pressure Control Open

Alternate Flashing 5 Minute Time Delay



should balance the air distribution system to ensure proper quiet airflow to all roomsin the home. This ensures a comfortable living space.

These simple mathematical formulas can be used to determine the CFM in a resi-dential or light commercial system. Electric resistance heaters can use:

CFM = volts x amps x 3.413

SHC x temp rise

Gas furnaces can use:

CFM = Output Capacity in BTUH*

SHC x temp rise

*Refer to furnace data plate for furnace output capacity. SHC = Sensible HeatConstant (see table below), an air velocity meter or airflow hood can give a moreaccurate reading of the system CFM. The measurement for temperature rise shouldbe performed at the indoor coil inlet and near the outlet, but out of direct line of sightof the heater element or heat exchanger. For best results, measure air temperatureat multiple points and average the measurements to obtain coil inlet and outlet tem-peratures.

10.0 EVACUATION AND LEAK TESTING10.1 EVACUATION PROCEDUREEvacuation is the most important part of the entire service procedure. The life andefficiency of the equipment is dependent upon the thoroughness exercised by theserviceman when evacuating air and moisture from the system.

Air or nitrogen in the system causes high condensing temperatures and pressure,resulting in increased power input and non-verifiable performance.

Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoricacid. This attacks motor windings and parts, causing breakdown.

• After the system has been leak-checked and proven sealed, connect the vacuumpump and evacuate system to 500 microns and hold 500 microns or less for atleast 15 minutes. The vacuum pump must be connected to both the high and lowsides of the system by connecting to the two pressure ports. Use the largest sizeconnections available since restrictive service connections may lead to falsereadings because of pressure drop through the fittings.

• After adequate evacuation, open both service valves by removing both brass ser-vice valve caps with an adjustable wrench. Insert a 3/16” [5 mm] or 5/16” [8 mm]hex wrench into the stem and turn counterclockwise until the wrench stops.

• At this time gauges must be connected to the access fitting on the liquid line

(small) service valve and the common suction port connected to the common suc-tion line between the reversing valve and compressor to check and adjust charge.

IMPORTANT: Compressors (especially scroll type) should never be used to evacu-ate the air conditioning system because internal electrical arcing may result in adamaged or failed compressor. Never run a scroll compressor while the system is ina vacuum or compressor failure will occur.

10.2 FINAL LEAK TESTINGAfter the unit has been properly evacuated and service valves opened, a halogenleak detector should be used to detect leaks in the system. All piping within the heatpump, evaporator, and interconnecting tubing should be checked for leaks. If a leakis detected, the refrigerant should be recovered before repairing the leak. TheClean Air Act prohibits releasing refrigerant into the atmosphere.

16

Altitude

(feet)

SENSIBLE HEAT

CONSTANT

(SHC)

ALTITUDE

(FEET)

SENSIBLE HEAT

CONSTANT

(SHC)

Sea Level 1.08 6000 0.87

500 1.07 7000 0.84

1000 1.05 8000 0.812000 1.01 9000 0.78

3000 0.97 10000 0.75

4000 0.94 15000 0.61

5000 0.90 20000 0.50



11.0 CHECKING REFRIGERANT CHARGECharge for all systems should be checked against the Charging Chart inside theaccess panel cover.

IMPORTANT:Use factory-approved charging method as outlined on the next 4

pages to ensure proper system charge.

11.1 CHARGING UNITS WITH R-410A REFRIGERANT

Charge for all systems should be checked against the Charging Chart inside theaccess panel cover.

IMPORTANT: Do not operate the compressor without charge in the system.

Addition of R-410A will raise high-side pressures (liquid, and discharge).

The following method is used for charging systems in the cooling and heatingmode. All steps listed should be performed to insure proper charge has been set.For measuring pressures, the service valve port on the liquid valve (small valve)and the service port on the suction line between the reversing valve and compressor are to be used.

CONFIRM ID AIR FLOW & COILS ARE CLEAN

Confirm adequate Indoor supply air flow prior to starting the system. See theTechnical Specification sheet for rated air flow for each ID/OD unit match. Airfilter(s) and coils (indoor & outdoor) are to be clean and free of frost prior to startin

the system. Supply Air flow must be between 375 and 450 cfm per rated cooling tprior to adjusting system charge. If a humidification system is installed disengage from operating prior to charge adjustment. Refer to the “Checking Airflow” sectionthis manual for further instruction.

! WARNINGThe top of the scroll compressor shell is hot. Touching the compressortop may result in serious personal injury.

! NOTICEThe optimum refrigerant charge for any outdoor unit matched with aCFL/CFM/H*L indoor coil/air handler is affected by the application.Therefore, charging data has been developed to assist the field technicianin optimizing the charge for all mounting configurations (UF – Upflow, DF

– downflow, LH – Left Hand Discharge, and RH – Right Hand Discharge).Refer to the charging chart inside the access panel cover on the unit andchoose the appropriate column for the specific application being installedor serviced. New installations utilizing either a CFL/CFM indoor coilinstalled on a gas furnace or an H*L air handler in the downflow or hori-zontal right hand discharge may require removal of refrigerant since thefactory charge could result in an overcharge condition.

! CAUTIONR-410A pressures are approximately 60% higher (1.6 times) than R-22pressures. Use appropriate care when using this refrigerant. Failure toexercise care may result in equipment damage or personal injury.

! NOTICESystem maintenance is to be performed by a qualified and certified technician.

! NOTICEVerify system components are matched according to the outdoor unitSpecification Sheet.



18

11.2 MEASUREMENT DEVICE SETUPStep 1. With an R410A gauge set, attach the high pressure hose to the access

fitting on the liquid line (small) service valve at the OD unit.

Step 2. Attach the low pressure hose to the common suction port connected to thecommon suction line between the reversing valve and compressor.

Step 3. Attach a temperature probe within 6” outside of the unit on the copperliquid line (small line). For more accurate measurements clean the copperline prior to measurement and use a calibrated clamp on temperatureprobe or an insulated surface thermocouple.

11.3 CHARGING BY WEIGHT

For a new installation, evacuation of interconnecting tubing and indoor coil isadequate; otherwise, evacuate the entire system. Use the factory charge shown in“Electrical and Physical Data” on page 6 of these instructions or on the unit dataplate. Note that the charge value includes charge required for 15 ft. [4.6 m] ofstandard-size inter-connecting liquid line without a filter drier. Calculate actualcharge required with installed liquid line size and length using:

1/4” [6.4 mm] O.D. = .3 oz./ft. [8.5 g/.30 m]

5/16” [7.9 mm] O.D. = .4 oz./ft. [11.3 g/.30 m]3/8” [9.5 mm] O.D. = .6 oz./ft. [17.0 g/.30 m]1/2” [12.7 mm] O.D. = 1.2 oz./ft. [34.0 g/.30 m]Add 6 oz. for field-installed filter drier.

With an accurate scale (+/– 1 oz. [28.3 g]) or volumetric charging device, adjustcharge difference between that shown on the unit data plate and that calculated forthe new system installation. If the entire system has been evacuated, add the totalcalculated charge.

IMPORTANT:Charging by weight is not always accurate since the application canaffect the optimum refrigerant charge. Charging by weight is considered a startingpoint ONLY. Always check the charge by using the charging chart and adjust asnecessary.CHARGING BY LIQUID SUB-COOLING MUST BE USED FOR FINALCHARGE ADJUSTMENT.

With thermostat in the “Off” position, turn the power on to the furnace or air handlerand the heat pump. Start the heat pump and the furnace or air handler with thethermostat.

11.4 GROSS CHARGING BY PRESSURESStep 1. Following air flow verification and charge weigh in, run the unit for a

minimum of 15 minutes prior to noting pressures and temperature.

IMPORTANT:Indoor conditions as measured at the indoor coil must be within 2°Fof the following during gross charge (pressure) evaluation:

Cooling Mode: 80°F Dry BulbHeating Mode: 70°F Dry Bulb

! NOTICEADJUST THE SYSTEM CHARGE BY WEIGHT FOR THE STRAIGHTLENGTH OF THE REFRIGERANT LINE SET.

FIGURE 3



Step 2. Note the Outdoor Dry Bulb Temperature, ODDB°F = _______°F. Unitcharging is recommended under the following outdoor conditions ONLY:

Cooling Mode ONLY: 55°F outdoor dry bulb and aboveHeating Mode ONLY: Between 40°F and 60°F outdoor dry bulb

Step 3. Locate and note the design pressures. The correct liquid and vaporpressures are found at the intersection of the Installed system and theoutdoor ambient temperature on the Charging Chart located on the insideof the control box cover of the outdoor unit.

Liquid Pressure: = ______psig; Vapor Pressure = ______psig

Step 4. If the measured liquid pressure is below the listed requirement for the givoutdoor and indoor conditions, add charge. If the measured liquid pressuis above the listed requirement for the given Outdoor and Indoor conditioremove charge.

11.5 FINAL CHARGE BY SUB-COOLINGStep 1. After gross charging note the designed Sub-Cool value. The correct sub-

cooling value is found at the intersection of the Installed system and theoutdoor ambient temperature on the Charging Chart located on the insideof the control box cover of the outdoor unit.

SC° from Charging Chart = _________°F.

IMPORTANT: Indoor conditions as measured at the indoor coil are required to bebetween 70°F and 80°F dry bulb for fine tune unit charge adjustment. Unit charginis recommended under the following outdoor conditions ONLY:

Cooling Mode ONLY: 55°F outdoor dry bulb and above

Heating Mode ONLY: Between 40°F and 60°F outdoor dry bulb

Step 2. Note the measured Liquid Pressure, Pliq = ______psig, as measured frothe liquid (small) service valve. Use the pressure temperature chart on thnext page to note the corresponding saturation temperature for R410A atthe measured liquid pressure.

Liquid Saturation Temperature, SAT°F= _________°F.

! NOTICEIf the Indoor temperature is above or below this range, run the system tobring the temperature down or run the electric heat/furnace to bring thetemperature within this range. System pressure values provided in theCharge Chart for outdoor dry bulbs corresponding to conditions outsideof ranges listed below, are provided as reference ONLY.

! NOTICEIf the Indoor temperature is above or below the recommended range, runthe system to bring the temperature down or run the electric heat/furnaceto bring the temperature up. System sub-cooling values provided in theCharge Chart for outdoor dry bulbs corresponding to conditions outsideof the above range, are provided as reference ONLY.

! NOTICEThe refrigerant pressures provided are for gross charge check ONLY.These pressure values are typical, but may vary due to application.Evaporator (indoor coil in cooling mode / outdoor coil in heating mode)load will cause pressures to deviate. Notice that all systems have uniquepressure curves. The variation in the slope and value is determined by thecomponent selection for that indoor/outdoor matched system. Thevariation from system to system seen in the table is normal. The valueslisted are for the applicable indoor coil match ONLY!



20

Step 3. Note the liquid line temperature, Liq° = __________°F, as measured froma temperature probe located within 6” outside of the unit on the copperliquid line (small line). It is recommended to use a calibrated clamp ontemperature probe or an insulated surface thermocouple.

Step 4. Subtract the liquid line temperature (Step 3) from the saturationtemperature (Step 2) to calculate Sub-Cooling. SAT°F______ - Liq°______ = SC°_______

Step 5. Adjust Charge to obtain the specified sub-cooling value. If the measuredsub-cool is below the listed requirement for the given outdoor and indoorconditions, add charge. If the measured sub-cool is above the listedrequirement for the given outdoor and indoor conditions remove charge.

IMPORTANT: Excessive use of elbows in the refrigerant line set can produceexcessive pressure drop. Follow industry best practices for installation. Installationand commissioning of this equipment is to be preformed by trained and qualifiedHVAC professionals. For technical assistance contact your Distributor ServiceCoordinator.

11.6 FINISHING UP INSTALLATION• Disconnect pressure gauges from pressure ports; then replace the pressure port

caps and tighten adequately to seal caps. Do not over tighten.

• Replace the service valve caps finger-tight and then tighten with an open-endwrench adequately to seal caps. Do not over tighten.

• Replace control box cover and service panel and install screws to secure servicepanel.

• Restore power to unit at disconnect if required.

• Configure indoor thermostat per the thermostat installation instructions and set

thermostat to desired mode and temperature.

12.0 ELECTRICAL WIRINGNOTE: Check all wiring to be sure connections are securely fastened, electricallyisolated from each other and that the unit is properly grounded.

TABLE 4

SATURATION

TEMP

(Deg. F)

R-410A

PSIG

SATURATION

TEMP

(Deg. F)

R-410A

PSIG

SATURATION

TEMP

(Deg. F)

R-410A

PSIG

SATURATION

TEMP

(Deg. F)

R-410A

PSIG

-150 - -30 17.9 35 107.5 100 317.4

-140 - -25 22 40 118.5 105 340.6

-130 - -20 26.4 45 130.2 110 365.1

-120 - -15 31.3 50 142.7 115 390.9

-110 - -10 36.5 55 156.0 120 418.0

-100 - -5 42.2 60 170.1 125 446.5

-90 - 0 48.4 65 185.1 130 476.5

-80 - 5 55.1 70 201.0 135 508.0

-70 - 10 62.4 75 217.8 140 541.2

-60 0.4 15 70.2 80 235.6 145 576.0

-50 5.1 20 78.5 85 254.5 150 612.8

-40 10.9 25 87.5 90 274.3

-35 14.2 30 97.2 95 295.3

! NOTICESystems should not be fine tune charged below 40°F outdoor dry bulb.



Field wiring must comply with the National Electric Code (C.E.C. in Canada) aany applicable local code.

12.1 POWER WIRINGIt is important that proper electrical power from a commercial utility is availablethe heat pump contactor. Voltage ranges for operation are shown in Table 4.

Install a branch circuit disconnect within sight of the unit and of adequate size handle the starting current (see Table 1).

Power wiring must be run in a rain-tight conduit. Conduit must be run through tconnector panel below the access cover (see Figure 1) and attached to the bottoof the control box.

Connect power wiring to contactor located in outdoor heat pump electrical box. (Swiring diagram attached to unit access panel.)

Check all electrical connections, including factory wiring within the unit and masure all connections are tight.

DO NOT connect aluminum field wire to the contactor terminals.

12.2 GROUNDINGA grounding lug is provided near the contactor for a ground wire.

12.3 CONTROL WIRING(See Figure 7)

If the low voltage control wiring is run in conduit with the power supply, Class I inslation is required. Class II insulation is required if run separate. Low voltage wirimay be run through the insulated bushing provided in the 7/8” [22.2 mm] hole in tbase panel, up to and attached to the pigtails from the bottom of the control boConduit can be run to the base panel if desired by removing the insulated bushing

A thermostat and a 24 volt, 40 VA minimum transformer are required for the contcircuit of the condensing unit. The furnace or the air handler transformer may

used if sufficient. See the wiring diagram for reference.

! WARNINGTurn off electric power at the fuse box or service panel before making anyelectrical connections.

Also, the ground connection must be completed before making line volt-age connections. Failure to do so can result in electrical shock, severepersonal injury or death.

! WARNINGThe unit must be permanently grounded. Failure to do so can cause elec-trical shock resulting in severe personal injury or death.

TABLE 4VOLTAGE RANGES (60 HZ)

Operating Voltage Range at Copeland

Nameplate Voltage Maximum Load Design Conditions forCompressors

208/230 (1 Phase) 187 - 253



22

13.0 FIELD INSTALLED ACCESSORIES13.1 COMPRESSOR CRANKCASE HEATER (CCH)

While scroll compressors usually do not require crankcase heaters, there areinstances when a heater should be added. Refrigerant migration during the off cyclecan result in a noisy start up. Add a crankcase heater to minimize refrigerationmigration, and to help eliminate any start up noise or bearing “wash out.”

NOTE: The installation of a crankcase heater is recommended if the system chargeexceeds the values in Table 5.

All heaters are located on the lower half of the compressor shell. Its purpose is todrive refrigerant from the compressor shell during long off cycles, thus preventing

damage to the compressor during start-up.At initial start-up or after extended shutdown periods, make sure the heater is ener-gized for at least 12 hours before the compressor is started. (Disconnect switch onand wall thermostat off.)

13.2 LOW AMBIENT CONTROL (LAC) – COOLING MODE ONLY - RXAD-A08This component senses compressor head pressure and shuts the heat pump fan offwhen the head pressure drops to approximately 220 PSIG [1516.8 kPa]. Thisallows the unit to build a sufficient head pressure at lower ambient in order to main-tain system balance and obtain improved capacity. Low ambient control should beused on all equipment operated below 70°F [21.1°C] ambient.

FIGURE 4CONTROL WIRING FOR AIR HANDLER

NOTES:

1. Jumper “E” to “W2” totransfer control ofsupplemental heat to1st stage when theemergency heat switchis on.

2. This wire turns on heat

for defrost, omit for mosteconomical operation.

3. Wire with colored tracingstripe.

B

W2

G

Y

W1

B

ODD

C

R

Air

Y G W2 E

Heat Pump Thermostat

Heat Pump

Outdoor Unit

Y

B

C R

R

D

C

Y

Field InstalledLine Voltage

-

WIRING INFORMATION

Factory Standard-

W/BL

G/BK

Y

W/BK

G/Y

BR

BL

R

NOTE: RED WIRE REQUIRED WITH RANCO DDL DEMAND DEFROST CONTROL.

TYPICAL THERMOSTAT:

HEAT PUMP WITH

ELECTRIC HEAT

TABLE 5MAXIMUM SYSTEM CHARGE VALUES 15 SEER

15 SEER Compressor Charge LimitModel Model Without CrankcaseSize Number Heat (1 Phase)

18 ZP16K5E 9.6 lbs. [66.2 kPa]24 ZP20K5E 9.6 lbs. [66.2 kPa]30 ZP24K5E 9.6 lbs. [66.2 kPa]36 ZP31K5E 9.6 lbs. [66.2 kPa]42 ZP34K5E 12 lbs. [82.7 kPa]

NOTE: Model sizes 48 and 60 have a factory installed crankcase heater.



13.3 HIGH PRESSURE CONTROL (HPC)This control keeps the compressor from operating in pressure ranges which ccause damage to the compressor. This control is in the low voltage control circuit.

High pressure control (HPC) is a manual reset which opens near 610 PSIG [4205kPa]. Do not reset arbitrarily without first determining what caused it to trip.

13.4 HEAT PUMP THERMOSTAT WARNING LIGHT KIT RXPX-D01This component senses a compressor lock out and tells the thermostat service ligto come on. This will let the homeowner know that service is needed on the syste

NOTE: Warning light on thermostat will come on during a 5 minute compressor timdelay and for 5 seconds during defrost while the compressor is off. Homeownshould only be concerned if light stays on for more than 5 minutes.

14.0 SERVICE14.1 SINGLE-POLE COMPRESSOR CONTACTOR (CC)

CAUTIONSingle-pole contactors are used on all standard single-phase units upthrough 5 tons. Caution must be exercised when servicing as only one legof the power supply is broken with the contactor.



24

15.0 TROUBLE SHOOTINGIn diagnosing common faults in the heat pump system, develop a logical thoughtpattern as used by experienced technicians. The charts which follow are not intend-ed to be an answer to all problems but only to guide the technician’s thinking.Through a series of yes and no answers, follow the logical path to a likely conclu-sion.

A novice technician should use these charts like a road map. Remember that thechart should clarify a logical path to the problem’s solution.

15.1 ELECTRICAL CHECKS FLOW CHART

Unit Running?

NO YES

Thermostat Problem? Go toMechanical Checks

YES NO for Cooling or HeatingRepair and Recheck

Transformer Problem?

YES NORepair and Recheck

Voltage on CompressorSide of Contactor?

YES NO

Run Capacitor Voltage on LineSide of Contactor?

Start Capacitor

NO YESPotential Relay

Circuit Breakers Compressor ContactorCompressor Internal or Fuses Open

Overload Open Hi Pressure Cut-Out

YES

Compressor Winding Open Hot Gas Sensor

Compressor Winding

Unit Wiring and Grounded Compressor Time-DelayConnections

Outdoor Fan Motor Unit Wiring andGrounded Connections

Grounded Capacitor

Replace Fusesor Reset Breakers

and Recheck System



15.2 COOLING MECHANICAL CHECKS FLOW CHART

Unit Running?

YES NO

Go to Electrical

Pressure problems? Checks Flow Chart

High Head Pressure Low Head Pressure Low Suction Pressure

Dirty Outdoor Coil Low on Charge Dirty Filters

Inoperative Outdoor Fan Open IPR Valve Dirty Indoor Coil

Overcharge Low Ambient Temperature Inadequate Indoor Air Flow

Recirculation of Inoperative Compressor Broken IndoorOutdoor Air Valves Blower Belt

Non-condensibles Outdoor Check Valve Inoperative Indoor BlowerClosed

Higher than Ambient Low on ChargeAir Entering Outdoor Coil

Restricted Indoor Restricted IndoorWrong Outdoor Fan Rotation Metering Device Metering Device

Restricted Restriction in System

Filter Drier

Recirculation ofReversing Valve Indoor Air

Failure

Wrong IndoorBlower Rotation

Inadequate Ducts

Outdoor Check Valve Closed

Restricted Filter Drier



26

15.3 HEATING MECHANICAL CHECKS FLOW CHART

Unit Running?

YES NO

Go to ElectricalPressure problems? Checks Flow Chart

High Head Pressure Low Head Pressure Low Suction Pressure

Dirty Filters Low on Charge Dirty Outdoor Coil

Dirty Indoor Coil Low Indoor Temperature Inadequate Air FlowOver Outdoor Coil

Inoperative Indoor Blower Open IPR Valve

Closed Indoor Inoperative OD FanOvercharge Check Valve (Check Defrost Control)

Inadequate Indoor Inoperative Compressor Low On ChargeAir Flow Valves

Non-condensibles Restricted Outdoor Restricted OutdoorMetering Device Metering Device

Broken IndoorBlower Belt Restricted Restriction in System

Filter Drier

Wrong Indoor Blower Rotation Closed Indoor Check ValveReversing ValveFailure

Inadequate Ducts Recirculation of Outdoor Air

RestrictedFilter Drier



15.4 DEFROST MECHANICAL CHECKS FLOW CHART

DEFROST SYSTEM

No Defrost Incomplete Defrost Excessive Defrost

Reversing Valve Stuck Poor Sensor Location Wrong Defrost ControlTimer Setting

No Defrost Timer Wrong Defrost ControlControl Power Timer Setting Poor Sensor Location

Failed Defrost Control Failed Defrost Relay Low System Charge(doesn’t stop O.D. Fan)

Failed Defrost Relay Thermostat Satisfies Wind AffectingDuring Defrost in Defrost

Loose DefrostSensor



28

System Problem

Overcharge *

Discharge Pressure

HighLow/

NormalHigh High

Undercharge Low Low Low Low

Liquid Line Restriction ** Low Low High Low

Low Evaporator Airflow High Low Low Low

Low Outside Ambient temperature Low Low High Low

TXV sensing bulb charge lost Low Low High Low

Poorly Insulated Sensing Bulb

* Superheat “normal” values may range anywhere from ~6 to ~20 degrees.

** High ratio of Discharge Pressure to Suction Pressure

High High Low High

Dirty outdoor Coil HighHigh/

NormalLow High

SuctionPressure

Sub-cooling Compressor Amps



SYMPTOM POSSIBLE CAUSE REMEDY

Unit will not run • Power off or loose electrical connection • Check for correct voltage at contactor in condensing unit

• Thermostat out of calibration-set too high • Reset• Defective contactor • Check for 24 volts at contactor coil - replace if contacts are

open• Blown fuses / tripped breaker • Replace fuses / reset breaker• Transformer defective • Check wiring-replace transformer• High pressure control open (if provided) • Reset-also see high head pressure remedy-The high pressure

control opens at 450 PSIG [3102 kPa]

Outdoor fan runs, compressor • Run or start capacitor defective • Replacedoesn’t • Start relay defective • Replace

• Loose connection • Check for correct voltage at compressor -check & tighten all connections

• Compressor stuck, grounded or open motor winding, • Wait at least 2 hours for overload to reset.open internal overload. If still open, replace the compressor.

• Low voltage condition • Add start kit components

Insufficient cooling • Improperly sized unit • Recalculate load

• Improper indoor airflow • Check - should be approximately 400 CFM [188.8 L/s] per ton.• Incorrect refrigerant charge • Charge per procedure attached to unit service panel• Air, non-condensibles or moisture in system • Recover refr igerant, evacuate & recharge, add f ilter dr ier

Compressor short cycles • Incorrect voltage • At compressor terminals, voltage must be ± 10% ofnameplate marking when unit is operating.

• Defective overload protector • Replace - check for correct voltage• Refrigerant undercharge • Add refrigerant

Registers sweat • Low indoor airflow • Increase speed of blower or reduce restriction - replace airfilter

High head-low vapor pressures • Restriction in liquid line, expansion device or filter drier • Remove or replace defective component• Flowcheck piston size too small • Change to correct size piston• Incorrect capillary tubes • Change coil assembly

High head-high or normal vapor • Dirty outdoor coil • Clean coilpressure - Cooling mode • Refrigerant overcharge • Correct system charge

• Outdoor fan not running • Repair or replace• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

Low head-high vapor pressures • Flowcheck piston size too large • Change to correct size piston• Defective Compressor valves • Replace compressor• Incorrect capillary tubes • Replace coil assembly

Low vapor - cool compressor - • Low indoor airflow • Increase speed of blower or reduce restriction - replace airiced indoor coil filter

• Operating below 65°F [18.3°C] outdoors • Add Low Ambient Kit• Moisture in system • Recover refrigerant - evacuate & recharge - add filter drier

High vapor pressure • Excessive load • Recheck load calculation• Defective compressor • Replace

Fluctuating head & vapor • TEV hunting • Check TEV bulb clamp - check air distribution on coil - replacepressures TEV

• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

Gurgle or pulsing noise at • Air or non-condensibles in system • Recover refrigerant, evacuate & rechargeexpansion device or liquid line

Disconnect all power to unit before servicing. Contactor may break only one side. Failure to shut off power cancause electrical shock resulting in personal injury or death.

15.5 GENERAL TROUBLE SHOOTING CHART

WARNING!



30

15.6 SERVICE ANALYZER CHART

COMPRESSOR OVERHEATING

SYMPTOMS POSSIBLE CAUSE CHECK/REMEDIES

High superheat Low charge Check system charge

Faulty metering device Restricted cap tube, TEV (TXV)

Power element superheatadjustment

Foreign matter stopping flow

High internal load Hot air (attic) entering return

Heat source on; mis-wired orfaulty control

Restriction in liquid line Drier plugged

Line kinked

Low head pressure Low charge

Operating in low ambienttemperatures

Suction or liquid line subjected Hot attic

to high heat source Hot water line

Low voltage Loose wire connections Check wiring

Dirty or pitted compressor Replace contactorcontactor contacts

Power company problem, Have problem corrected beforetransformer diagnosis continues

Undersized wire feeding unit Correct and complete diagnosis

High voltage Power company problem Have problem corrected

High head pressure Overcharge Check system charge

Dirty heat pump coil Clean coil

Faulty or wrong size Replace fan motorheat pump fan motor

Faulty fan blade Replace fan bladeor wrong rotation

Replace with correct rotation motorRecirculation of air Correct installation

Additional Heat Source Check for dryer vent near unit

Check for recirculation fromother equipment

Non-condensibles Recover refrigerant, Evacuate andrecharge system

Equipment not matched Correct mis-match

Short cycling of compressor Faulty pressure control Replace pressure control

Loose wiring Check unit wiring

Thermostat Located in supply air stream

Differential setting too close

Customer misuse

TEV Internal foreign matter

Power element failure

Valve too small

Distributor tube/tubes restricted

Capillary tube Restricted with foreign matter

Kinked

I.D. reduced from previouscompressor failure



SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES

Short cycling of compressor (cont.) Low charge Check system charge

Low evaporator air flow Dirty coil

Dirty filter

Duct too small or restricted

Faulty run capacitor Replace

Faulty internal overload Replace compressor

Faulty Compressor Valves Fast equalization/ Replace compressor and examine

Low pressure difference system to locate reason

ELECTRICAL


Voltage present on load side Compressor start components Check start capacitorof compressor contactor andcompressor won’t run Check potential relay

Run capacitor Check with ohmmeter

Internal overload Allow time to reset

Compressor windings Check for correct ohms

Voltage present on line side of Thermostat Check for control voltage to com-pressor contactor only contactor coil

Compressor control circuit High pressure switch

Low pressure switch

Ambient thermostat

Solid state protection control orinternal thermal sensors

Compressor timed off/oncontrol or interlock

No voltage on line side Blown fuses or tripped circuit breaker Check for short in wiring or unitof compressor contactor

Improper wiring Re-check wiring diagram

Improper voltage High voltage Wrong unit

Power supply problem

Low voltage Wrong unit

Power supply problem

Wiring undersized

Loose connections

Single Phasing (3 phase) Check incoming power and fusing

CONTAMINATION


Moisture Poor evacuation on installation In each case, the cure is the same.or during service Recover refrigerant. Add filter drier,

evacuate and re-charge

High head pressure Non-condensibles air

Unusual head and suction readings Wrong refrigerant

Foreign Matter-copper filings Copper tubing cuttings

Copper oxide Dirty copper piping

Welding scale Nitrogen not used

Soldering flux Adding flux before seatingcopper part way

Excess soft solder Wrong solder material



32

LOSS OF LUBRICATION


Compressor failures Line tubing too long Add oil to the recommended level

Line tubing too large Reduce pipe size to improveoil return

Low suction pressure Low charge Check system charge

Refrigerant leaks Repair and recharge

Cold, Noisy compressor - Slugging Dilution of Oil with Refrigerant Observe piping guidelines

Noisy compressor Migration Check crankcase heater

Cold, sweating compressor Flooding Check system charge

Low Load Reduced air flow Dirty filter

Dirty coil

Wrong duct size

Restricted duct

Thermostat setting Advise customer

Short cycling of compressor Faulty pressure control Replace control

Loose wiring Check all control wires

Thermostat In supply air stream,out of calibration,

Customer misuse

FLOODED STARTS

SYMPTOMS POSSIBLE CAUSES CHECK OR REMEDIES

Liquid in the compressor shell Faulty or missing crankcase heater Replace crankcase heater

Too much liquid in system Incorrect piping Check Piping guidelines

Overcharge Check and adjust charge

SLUGGING


On start up Incorrect piping Review pipe size guidelinesTEV hunting when running Oversized TEV Check TEV application

FLOODING


Poor system control Loose sensing bulb Secure the bulb and insulateusing a TEV

Bulb in wrong location Relocate bulb

Wrong size TEV Use correct replacement

Improper superheat setting Adjust, if possible;

Replace, if not

Poor system control Overcharge Check system chargeusing capillary tubes

High head pressures Dirty heat pump

Restricted air flow

Recirculation of air

Evaporator air flow too low Adjust air flow to 400 CFM[188.8 L/s] /Ton



THERMOSTATIC EXPANSION VALVES


High Superheat, Low Suction Pressure Moisture freezing and blocking valve Recover charge, install filter-drier,evacuate system, recharge

Dirt or foreign material blocking valve Recover charge, install filter-drier,evacuate system, recharge

Low refrigerant charge Correct the charge

Vapor bubbles in liquid line Remove restriction in liquid line

Correct the refrigerant chargeRemove non-condensible gases

Size liquid line correctly

Misapplication of internally equalized Use correct TEVvalve

Plugged external equalizer line Remove external equalizer linerestriction

Undersized TEV Replace with correct valve

Loss of charge from power Replace power head or completehead sensing bulb TEV

Charge migration from sensing bulb Ensure TEV is warmer thanto power head (Warm power head sensing bulbwith warm, wet cloth. Does valveoperate correctly now?)

Improper superheat adjustment Adjust superheat setting counter-(Only applicable to TEV with adjustable clockwisesuperheat settings)

Valve feeds too much refrigerant, Moisture causing valve to stick open. Recover refrigerant, replace filter-with low superheat and higher than drier, evacuate system and then nor-mal suction pressure recharge

Dirt or foreign material causing Recover refrigerant, replace filter-valve to stick open drier, evacuate system and

recharge

TEV seat leak (A gurgling or hissing Replace the TEVsound is heard AT THE TEV duringthe off cycle, if this is the cause.)

NOT APPLICABLE TO BLEEDPORT VALVES.

Oversized TEV Install correct TEV

Incorrect sensing bulb location Install bulb with two mountingstraps, in 2:00 or 4:00 position onsuction line, with insulation

Low superheat adjustment Turn superheat adjustment(only applicable to TEV with clockwiseadjustable superheat setting)

Incorrectly installed, or restricted Remove restriction, or relocateexternal equalizer line external equalizer

Compressor flood back upon start up Refrigerant drainage from flooded Install trap riser to the top of theevaporator evaporator coil

Compressor in cold location Install crankcase heater oncompressor

Any of the causes listed under Any of the solutions listed underSymptoms of Problem #2 Solutions of Problem #2



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THERMOSTATIC EXPANSION VALVES


Superheat is low to normal Unequal evaporator circuit loading Ensure air flow is equally distributedwith low suction pressure through evaporator

Ensure proper piston is inserted intoRCBA or RCHA evaporator coildistributor

Check for blocked distributortubes

Low load or airflow entering Ensure blower is moving proper airevaporator coil CFM [L/s]

Remove/Correct any air flowrestriction

Superheat and suction Expansion valve is oversized Install correct TEVpressure fluctuate (valve is hunting)

Sensing bulb is affected by liquid Relocate sensing bulb in anotherrefrigerant or refrigerant oil flowing position around the circumference ofthrough suction line the suction line

Unequal refrigerant flow through Ensure proper distributor piston isevaporator circuits inserted in RCBA or RCHA coil

Ensure sensing bulb is located

properlyCheck for blocked distributortubes

Improper superheat adjustment Replace TEV or adjust superheat(only possible with TEV havingsuperheat adjustment)

Moisture freezing and partially Recover refrigerant, change filter-blocking TEV drier, evacuate system and

recharge

Valve does not regulate at all External equalizer line not connected Connect equalizer line in properor line plugged location, or remove any blockage

Sensing bulb lost its operating charge Replace TEV

Valve body damaged during soldering Replace TEV

or by improper installation



IMPORTANT: SHIPPING STRAP REMOVAL

Notice: Failure to remove strap prior to operation

could result in increased internal tubing stress.

Plastic strap can be cut off from the exterior of the

unit and left inside of the unit.



36

16.1 ENHANCED DEFROST CONTROL - PSC MOTORFIGURE 5

WIRINGDIAGRAM/DIAGRAMADECONEXIONADO

DIAGNOSTIC CODES/

CÓDIGOSDE DIAGNÓSTICOFAN

MOTOR/

MOTOR

VENT.

Y1OUT/SALIDAY1

TEST/PRUEBA

PRESS/PRES.

WIRING SCHEMATIC/ESQUEMADE CONEXIONADO

Y1OUT/SALIDAY1

COMPONENTCODE/CÓDIGODE COMPONENTES

AMBIENTSENSOR/SENSOR AMBIENTALCOMPRESSOR CONTACTOR/CONTACTOR DE COMPRESORCRANKCASE HEATER/CALENTADOR DEL C ÁRTERCRANKCASE HEATER CONTROL/CONTROL DEL

CALENTADOR DEL CARTERCOMPRESSOR/COMPRESORDEFROST CONTROL/CONTROL DEL DESCONGELACIÓNDEFROST COIL SENSOR/SENSOR DEL SERPENTÍN DE

DESCONGELACIÓNGROUND, CHASSIS/TIERRA, CHASISHIGH PRES. CUT OUT CONTROL/CONTROL DE CORTE

POR ALTA PRESIÓNLOW AMBIENT COOLING CONTROL/CONTROL DE

ENFRIAMIENTO, BAJATEMP. AMBIENTELOW AMBIENT RELAY/RELÉ, BAJA TEMP. AMBIENTELOW PRESSURE CUT OUT CONTROL/CONTROL DE CORTE

POR BAJA PRESIÓNOUTDOOR FAN MOTOR/MOTORVENTILADOR EXTERIOROPTIONAL/OPCIONALRUN CAPACITOR/CAPACITOR DE MARCHAREVERSINGVALVE/VÁLVULA DE INVERSIONSTART CAPACITOR/CAPACITOR DE ARRANQUESTART RELAY/RELÉ DE ARRANQUEWARNING RELAY/RELÉ DE ALARMA

ASCCCCHCHC

COMPDFCDS

GNDHPC

LAC

LARLPC

OFMOPTRCRVSCSRWR

NOTES:/NOTAS:

1. CONNECTORS SUITABLE FOR USEWITH COPPER CONDUCTORS ONLY./CONECTORES APTOS PARA UTILIZARCON CONDUCTORES DE COBRE UNICAMENTE.

2. COMPRESSOR MOTORTHERMALLY PROTECTED AND ALL 3 PHASE ARE PROTECTED UNDER PRIMARYSINGLE PHASE CONDITIONS./MOTOR DEL COMPESSOR CON PROTECCIÓNTÉRMICA,Y LAS 3 FASESPROTEGIDAS EN CONDICIONES MONOFASICAS DE PRIMARIO.

3. CONNECT FIELDWIRING IN GROUNDED RAINTIGHT CONDUITTO 60 HERTZ FUSE DISCONNECT,VOLTAGE ANDPHASE PER RATING PLATE./HAGA EL CONEXIONADO DE C AMPO EN UN CONDUCTO A PRUEBA DE LLUVIAYCONECTADO ATIERRA A LA ALIMENTACION DE 60 HERTZ, CON DESCONECTADFOR FUSIBLE,TENSIÓNY CANTIDAD DE FASES SEGUN LA PLACA DE CARACTERÍSTICAS.

4. LOWVOLTAGE CIRCUITTO BE N.E.C. CLASS 2WITH A CLASS 2TRANSFORMER 24VOLT, 60 HERTZ./EL CIRCUITO DE BAJATENSIÓN SERÁ CONFORME A LA CLASE 2 DE N.E.C. CON UNTRANSFORMADOR DE24VOLTS, 60 HERTZ, DE CLASE 2.

5. TOTHERMOSTAT SUB BASE, REFER TO SYSTEMSCHEMATICS OR SCHEMATICS ON INDOOR SECTION FORLOWVOLTAGE CONTROLWIRING./A LA SUB BASE DETERMOSTATO POR EL CONEXIONADO DEL CONTROLDE BAJA TENSION, CONSULTE EL DIAGRAMA DEL SISTEMA O EL DIAGRAMA DE LA SECCIÓN INTERIOR.

6. THIS WIRE IS USEDTOTURN ON STRIP HEAT DURING DEFROST. OMIT CONNECTION FOR MOST ECONOMICALOPERATIOIN./ESTE CABLE SE UTILIZA PARA ENCENDER EL CALENTADOR DE TIRA DURANTE LADESCONGELACIÓN. OMITA LA CONEXION PARA QUE EL FUNCIONAMIENTO SEA MÁS ECONOMICO.

7. TO HEAT PUMP MONITOR 2.5VA. MAX.WHEN USED./AL MONITOR DE LA BOMBA DE CALOR, 2.5VA MAX.,SI SE USA.

8. THIS COMPONENT IS ENERGIZED IN HEATING MODE./ESTE COMPONENTE ESTÁ ENERGIZADO EN EL MODODE CALENTAMIENTO.

9. IF LAC/LAR IS NOT USED, CONNECT BLACKWIRE FROM OFMTO OFC FAN MOTOR./SI NO SE UTILIZA LAC/LAR,CONECTE EL CABLE NEGRO DEL OFM A‘FAN MOTOR’DEL DFC.

10. BLACKWIRE FROM SR 5 TO CC T1 DELETEDWHEN PTCR IS USED./EL CABLE NEGRO DEL SR 5 AL CC T1SE ELIMINA CUANDO SE UTILIZA ELTERMISTOR DE ARRANQUE PTCR .

WIRECOLORCODE/CÓDIGODE COLORESDE CABLES

BK _ _ BLACK/NEGROBR _ _ BROWN/MARRÓNBL _ _ BLUE/AZULG _ _ _GREEN/VERDEGY_ _ GRAY/GRIS

O _ _ _ORANGE/NARANJAPR _ _ PURPLE/PURPURAR _ _ _RED/ROJOW_ _ _WHITE/BLANCOY_ _ _ YELLOW/AMARILLO

WIRINGDIAGRAM/DIAGRAMADE CONEXIONADO

REMOTE HEAT PUMP/BOMBADE CALOR REMOTASINGLE PHASEWITH PSC/

MONOFÁSICA CON CAPACITOR PERMANENTE PSCDEMAND DEFROST CONTROL/

CONTROL DE DESCONGELACIÓNPOR DEMANDA

LINEVOLTAGE/TENSIÓN DE LÍNEAFACTORY STANDARD/ ESTANDAR DE FABRICAFACTORY OPTION/ OPCIÓN DE FABRICAFIELD INSTALLED/ INSTALADO EN EL SITIO

LOWVOLTAGE/BAJATENSIONFACTORY STANDARD/ ESTANDAR DE FÁBRICAFACTORY OPTION/ OPCIÓN DE FÁBRICAFIELD INSTALLED/ INSTALADO EN EL SITIO

REPLACEMENTWIRE/CABLE DE REEMPLAZOMUST BETHE SAMESIZE AND TYPE OF INSULATION ASORIGINAL 105°C MIN. / DEBE SER DEL MISMO CALIBREYTIPO DE AISLAMIENTO

QUE EL ORIGINAL 105°C MIN.

WARNING/ADVERTENCIACABINET MUST BE PERMANENTLY GROUNDED AND CONFORMTO I.E.C., N.E.C.,C.E.C. AND LOCAL CODES AS APPLICABLE./ EL GABINETE DEBE ESTAR CONECTADO ATIERRA EN FORMA PERMANENTEY CUMPLIR CON LAS NORMASDE I.E.C., N.E.C.,C.E.C.Y LOS CODIGOS LOCALES QUE SEAN APLICABLES.

WIRING INFORMATION/INFORMACIÓNSOBRE CONEXIONADO

16.0 WIRING DIAGRAMS



16.2 ENHANCED DEFROST CONTROL - ECM MOTORFIGURE 6



38

Rheem Condensor Service Manual 15PJL

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